Waterproof/breathable technical apparel

ABSTRACT

The apparel is constructed from various combinations of layers of materials with moisture transfer properties. A first liner of moisture transfer fabrics abuts a second layer of structural material such as a foam. The second layer can abut a breathable membrane and/or an insulating material. Finally, carefully selected outer fabrics complete the combination to provide apparel with improved performance characteristics. The outer fabrics are treated in various ways to enhance performance.

This is a Continuation-in-Part application of Ser. No. 08/832,815, filedApr. 4, 1997, now abandoned, which is a Continuation-in-Part applicationof Ser. No. 08/747,340, filed Nov. 12, 1996, now U.S. Pat. No.5,738,937.

FIELD OF THE INVENTION

The present invention relates to apparel (garments) which isparticularly suited to transfer moisture away from an individual.Particularly, the present invention relates to apparel constructedaccording to a moisture transfer system having a combination of layersthat removes moisture away from an individual while also beingcomfortable and aesthetically pleasing in appearance.

BACKGROUND OF THE INVENTION

Various types of apparel are known in the prior art. However, none ofthese provide the advantages provided by the present invention. Inparticular, the types of apparel known in the art do not take advantageof the new advances in materials and fabrics that have been made inrecent years. Additionally, new apparel known in the prior art do notteach a moisture transfer system based upon specific combinations oflayers as taught in the present invention.

SUMMARY OF THE INVENTION

The present inventor has recognized the deficiencies in the apparelknown in the prior art and has designed new apparel that is capableovercoming those deficiencies. More specifically, the present inventiondiscloses a carefully selected combination of layers of specificmaterials that enable moisture transfer, while at the same timeproviding comfort to the individual wearing the apparel.

An object of the present invention is to provide apparel that canquickly transfer moisture away from an individuals body so that theindividual can feel more comfortable.

Another object of the present invention is to provide individualsinvolved in activities such as in-line skating, snowboarding, hiking,etc., with active wear that is more functional and can better deal withthe additional moisture that is generated by such individuals whileinvolved in such activities.

Yet another object of the present invention is to provide a combinationof foam-like materials and fabrics-like materials resulting from thelatest technological advances in a manner unknown in the prior art.

These and other objects, features, and advantages of the presentinvention will become more apparent in view of the following detaileddescription of the preferred embodiments in conjunction with thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 generally illustrates the layers forming the combinationaccording to an embodiment of the present invention.

FIGS. 2–6 illustrate various applications of the different combinationsof materials utilized according to the present invention.

DETAILED DESCRIPTION OF THE PREFFERED EMBODIMENTS

A detailed description of the preferred embodiments will now bedescribed in conjunction with the Figures. It should be understood thatthese embodiments are set forth for purposes of explanation only and arenot to be interpreted as the only application the present invention.

The apparel illustrated in FIGS. 2–6 include shirts and jackets.Although not specifically illustrated, all other types of apparel can bemanufactured according to the present invention. The application of thisinvention to other types of apparel could be easily accomplished by onewith ordinary skill in the art.

FIG. 1 generally illustrates the three layers that are a result of apreferred embodiment of the present invention, namely a first (inner)layer 10, a second layer 20, a third layer 30 and a fourth (outer) layer40. These layers are attached to each other either by mechanical bonding(or stitch bonding, such as that performed by Tietex, Inc. or Xymidgroup of DuPont®), lamination (flame lamination, for example), or acombination of these two. Mechanical bonding can be performed usingnylon or LYCRA® (spandex) thread or the like. Other equivalent methodsmay also be employed. Furthermore, as mentioned later, if encapsulationtechnology is used for the material(s) used as the fourth layer 40, thenthe fourth layer 40 is preferably not laminated to the third layer 30.This is due to the nature of encapsulated materials. A detaileddiscussion of the materials preferably used in these layers follows.

The first layer 10 is the layer that is closest to an individuals body.First layer 10 is preferably selected from the following list of innermoisture transfer materials:

Anti-fungal, anti-microbial polypropylene and LYCRA (spandex® blend(INNOVA);

Anti-fungal, anti-microbial polypropylene blend military fleece byDeercreek Fabrics;

Anti-fungal, anti-microbial polypropylene cotton blend (ALPHA);

INTERA-Moisture Transfer Fabrics (by Argmont), which include polyester,or blends including polyester, nylon, wool cotton, etc.;

Field sensor polyester blend knitted fabric Toray AF 123PD;

Looped polyester terry or polypropylene blend;

Aqua dry treated fabric blends of polyester (distributed by TeijinShojin;

Spun polyester or LYCRA® (spandex) or cotton blend with a wicking finishor the like (distributed by Teijin Shojin);

COOL MAX fabrics; or

LYCRA® (spandex/polyester blends or the like. The first layer 10 abuts asecond layer 20 and is attached thereto by lamination, mechanicalbonding, ultra sonic bonding or the like. The second layer 20, inaddition to its moisture transfer characteristics, provides somestructural support for the apparel and can either be made of a singlematerial or a combination of materials as set forth below.

Second layer 20 may be a reticulated, open cell or reticulated open cellhydrofilic foam with a non-woven top sheet, made by DuPont®, or thelike. All the foam materials discussed herein can be AQUAZONE, made byFoamex, or the like. The non-woven top sheet may vary in composition.The preferred composition for the top sheet is wood pulp, cotton, rayon,polypropylene, LYCRA® (spandex) (or a combination of two or more ofthese). The top sheet is usually provided on one side of the foam, butcan be provided on both sides of the foam, such as in extremeperformance apparel for example. The foam can be of any thickness,preferably between 1/16″ and 3/16″. The top sheet may also be eliminatedin some performance apparel.

If desired, an Outlast membrane may be laminated between first layer 10and second layer 20 or Frisby Technology may be embedded into the secondlayer 20. The Outlast membrane by Gateway Technologies may be laminatedto the foam or the Frisby Technology may be embedded in the AQUAZONE, orthe like. Both Gateway Technology and Frisby Technology aremicroencapsulated technology which depending on the application canprovide either warmth or cooling. If Frisby Technologies is selected,hydrophilic foam is used in the layer 20, and is referred to asCOMFORTEMP. This invention employs AQUAZONE which may or may not beembedded with the Frisby Technology, but COMFORTEMP or ahydrophilic/open cell foam may also be used and may be laminated to theOutlast membrane.

A number of patents have been issued to Triangle Research & DevelopmentCorp. disclosing details related to the processes now being employed byGateway Technologies and Frisby. For example, U.S. Pat. Nos. 4,756,958and 5,366,801 are directed to fibers and fabrics with reversibleenhanced thermal properties, respectively. The disclosures of these twopatents are hereby incorporated by reference. Other patents assigned toTriangle Research & Development Corp., that are related by subjectmatter and have overlapping inventorship, include U.S. Pat. Nos.5,415,222, 5,290,904 and 5,244,356. These patents are also herebyincorporated by reference.

The combination of the foam and top sheet forming second layer 20 can beproduced in at least two different ways. According to one way, secondlayer 20 is produced by laminating a top sheet to the foam. According toanother way, the second layer 20 is a cellular elastomeric composite inwhich the top sheet and the foam have already been combined. In someapplications, layer 20 can be omitted.

The third layer 30 abuts the non-woven top sheet of the second layer 20.The third layer 30 includes a breathable membrane, such as preferablyTX1540 by Shawmut Mills, WITCOFLEX SUPER DRY film by Baxenden Chemicals(a water based hydrophilic polyurethane membrane) or the like. Thewaterproof/breathable membranes may be combined with Outlast Technologyor may be next to the Frisby Technology embedded into the AQUAZONE orthe like. The breathable/membrane absorbs the outgoing moisture andtransfers it to the garment surface while providing a waterproof barrierfor the garment. The membrane is laminated to the inner side of theouter fabric. If the outer fabric is encapsulated or structurally wovento repel water the breathable membrane is not necessary. For colderconditions, such as for temperatures below 32° F., an additionalinsulating layer may also provided along with the Outlast membrane orFrisby Technologies. This insulating layer is preferably THERMOLITE thinor EXTREME (manufactured by DuPont®) or a hydrofilic foam. FrisbyTechnology can be used in conjunction with the foam materials andespecially in conjunction with THERMOLITE. Alternatively, this layer,like others, can be omitted entirely in certain applications.

The fourth, or outer, layer 40 abuts either the breathable membrane orthe insulating material, if used, of the third layer 30. If the outerlayer is a material that is encapsulated or if it is a performancefabric such as DERMIZAX by Toray or MICROFT, which is distributed byTeijin Limited, then the third layer 30 abuts the fourth layer 40, butis not laminated thereto. The following is a list of outer moisturetransfer materials that could be used as the outer layer 40:

Cotton polyester blend with a breathable membrane (several choices);

Cotton blend encapsulated;

Cotton denim or chino encapsulated or waterproof breathable membrane;

⅔ ply supplex encapsulated or waterproof breathable membrane;

6-ply TASLAN encapsulated or waterproof breathable membrane;

TUDOR by Travis encapsulated or waterproof breathable membrane;

MOJAVE/TWISTER by Travis encapsulated or waterproof breathable;

Codura® encapsulated or waterproof breathable membrane;

KEVLARS by Schoeller encapsulated or membrane;

MICRO-TECHNICAL II SANDED or MICRO-TECHNICAL III SANDED by Brookwoodencapsulated or breathable membrane;

CITATION SANDED or JET-LAUND by Brookwood encapsulated or breathablemembrane;

Encapsulated supplex by Toray;

DERMIZAX Fabrics by Toray;

ENTRANT GIL by Toray;

MICROFTSUPER-MICROFT distributed by Teijin Shojin or ASF;

GYMSTAR PLUSGYMSTAR PLUS by Unitika;

TUFLEX-HR by Unitika;

Schoeller DRYSKIN;

Schoeller DYNAMIC EXTREME;

Schoeller KEPROTEC;

Schoeller DYNATEC;

Schoeller KEPROTECT with INOX;

Micro-polyester fabrics distributed by Teijin Shojin;

Structurally knitted acrylic, wool, with or without encapsulation (madeby Toray), distributed by Teijin Shojin or ASF Group, Kyodo Sangyo Co.Ltd. (a structurally knitted fabric that repels water);

Vinyl materials with a nonwoven backing and plastics fabrics, by TessileFlorentina, Baikfan or Teijin Shojin, these groups include ERREBI,101659-01669-01676-1271, 57006-800 and 43005-870;

STOMATEX, which is a neoprene type of material that is breathable;

DARLEXX, which is a LYCRA® (spandex) type of material and is to be usedin the underarm portions of certain apparel

Ripstop Hardline fabric; and

Wool and wool blends which include one or more of the following:acrylic, LYCRA® (spandex), polyester and nylon. These fabrics are madeof yarns and are hydrophobic. Wool and wool blends are provided byEuromotte, Inc. of Belgium and/or toray in Japan. These fabrics areeither pure wool, wool blends or acrylics that are knitted withhydrophilic yarns so as to be waterproof. This is in effect anencapsulation process.

All of the above, used as the fourth layer 40, are laminated with abreathable membrane, encapsulated, covered by a waterproof film or arewoven man-made fabrics structurally knitted or woven to repel water. Thestructurally woven or knitted fabrics do not require encapsulation orbreathable membranes to waterproof the garment. The preferred waterprooffabrics are MICROFT by Teijin Shojin, GYMSTAR PLUS and TUFLEX-HR both byUnitika, Ltd. Another preferable fabric is a structurally knittedacrylic or acrylic blends, which may be encapsulated and distributed byASF and made by Toray, for example. A number of marketed waterproofexterior films could be added as an option for snowboard apparel,especially for areas covering an individuals knees, elbows and buttressarea. These films (DWRs) are applied by fabric manufacturers themselves.This film may or may not be used with encapsulation but may be used incombination with the waterproof/breathable membrane systems. Highabrasive materials, preferably KEVLAR fabrics by Schoellar may also beadded along areas of pants, elbows, pocket lines, cuffs and buttressareas.

All technical apparel will preferably have seams hot melted oradhesively sealed to prevent moisture from entering along stitch lines.The Extreme apparel will add zipped underarm vents to aid in moisturerelease and will contain a hydrophilic open cell foam collar band andwrist band cover by inner fabric selection to absorb excess moisture andtransport it away from an individual. A rain gut along the front shirtzipper line may be added to aid in moisture transfer.

FIGS. 2–6 illustrate various applications of the present invention ascontemplated by the inventor. These applications are discussed by way ofexample only. More specifically, FIGS. 2–6 illustrate various styles ofshirts or jackets incorporating the present invention is differentcombinations. The reference numerals 101–109 represent various areas ofthe different types apparel constructed from the following combinationsof materials. It is once again mentioned that Outlast can be combinedwith the materials listed below, although not specifically mentioned. Inother words, Outlast or Frisby Technologies can be combined with thefoam materials, the breathable membranes, the THERMOLITE or any of theouter fabrics. Outlast or Frisby Technologies can also be combined withencapsulation, by Nextec, for use in the outer layer 40. Of course,Outlast or Frisby Technologies can also be used by itself.

Numeral 100 is preferably formed by a layer 40 formed from a cottonblend fabric that is encapsulated and may include denim and chinofabrics. Inside of layer 40 is a layer 20 which is a cellularelastomeric composite of a hydrophilic ⅛″ foam having a non-woven topsheet. Inside of layer 20 is a layer 10 of any of the inner linermaterials listed above in connection with layer 10. According to thisapplication, layer 30 is omitted.

Numeral 200 has a layer 40 of an encapsulated cotton blend abuttingTHERMOLITE EXTREME, MICROLOFT or the like, or abutting a hydrophilic,open cell foam or a reticulated foam (either or in combination as acomposite). Inside layer 40 is a layer 20 which is a non-woven and foam,the foam being preferably AQUAZONE. Inside layer 20 is a layer 10 whichcan be any of the inner liner materials mentioned above in connectionwith layer 10. Layer 30 is omitted.

Numeral 300 has a layer 40 that is a cotton, acrylic, polyester or ablend. Inside layer 40 is a layer 30 which is a waterproof breathablemembrane. Inside layer 30 is a layer 10 which is one of various innerliner materials. Layer 20 is omitted.

Numeral 400 has a layer 40 that is a cotton/acrylic/polyester blend.Inside layer 40 is layer 30 which is a waterproof breathable membrane.Inside layer 30 is a layer 20 which is either THERMOLITE orreticulated/open cell hydrofilic foam with or without Frisby Technology.If foam is used, AQUAZONE is preferred. Also, the THERMOLITE and foammay be combined. Inside layer 20 is layer 10 of one of the inner linermaterials.

Numeral 500 has a layer 40 of 2/4 Supplex, 6-ply TASLAN, Cordura,Micro-Technical II and III, CITATION SANDED, TUDOR, MOJAVE, TWISTERTravis fabrics, KEVLAR fabrics, laminated breathable membrane orencapsulated outer fabrics. Inside layer 40 is a layer 30 of THERMOLITE.Instead of THERMOLITE, a reticulated/open cell hydrophilic foam may beused, or may be combined with the THERMOLITE. Inside layer 30 is a layer20 of a cellular elastomeric composite. Inside layer 20 is a layer 10 ofone of the inner liner materials.

Numeral 600 has a layer 40 of GYMSTAR PLUS or SUPER-MICROFT structuralconstructed water-repellent fabrics. Inside layer 40 is a layer 20 of anon-woven and foam composite with or without a breathable membrane 30between layers 40 and 20. Inside layer 20 is a layer 10 of one of theinner liner materials.

Numeral 700 has a layer 40 of GYMSTAR PLUS, SUPER-MICROFT, TUFLEX-HR,abutting THERMOLITE EXTREME or hydrofilic foam or a combination ofthese. Inside this layer 40 is a layer 20 which is a cellularelastomeric composite or a foam with a non-woven top sheet laminatedthereto. A breathable membrane 30 can optionally be added between layers20 and 40.

Numeral 800 has a layer 40 made of one of the possible fabrics mentionedabove, except GYMSTAR PLUS or SUPER-MICROFT waterproof breathablemembrane. Inside layer 40 is a layer 20 which is a cellular elastomericcomposite. Inside layer 20 is a layer 10 of one of the inner linermaterials.

Numeral 900 has a layer 40 made of one of the possible fabrics mentionedabove, except GYMSTAR PLUS or SUPER-MICROFT waterproof breathablemembrane. Inside layer 40 is a layer 30 of Themolite or a layer 20 ofreticulated or hydrophilic open cell foam with a nonwoven top sheet.Inside layer 30 or layer 20 is a layer 10 of one of the inner linermaterials.

The examples presented above illustrate how various combinations of thepresent invention can be realized is different parts of different typesof apparel. Other variations are also possible given the range ofcombinations that are possible.

The microfiber technology disclosed above is rapidly developing andchanging and has greatly increased the potential for improvedperformance of such products such as performance apparel, provided thatthey are properly utilized as in the present invention. These newproducts are part of rapidly developing fabric technology. The presentinvention employs a combination of fabrics, foam layers, nonwovens,spacer fabrics, breathable membranes, encapsulated technology,structural woven water repellent fabrics, or waterproof film coatings insuch combinations that increase the performance of the products in whichthey are used as well as increase breathability. Thewaterproof/breathable membranes have also only recently developed andare believed to be less than ten years old.

While the present invention has been described above in connection withthe preferred embodiments, one of ordinary skill in the art would beenabled by this disclosure to make various modifications to theseembodiments and still be within the scope and spirit of the presentinvention as embodied in the appended claims.

1. A moisture transfer apparel to be worn by individuals engaged inactivities that generate moisture comprising, on at least a portion ofthe apparel, a combination of layers comprising: a first layer, closestto the individual, the first layer being an inner moisture transfermaterial; a second layer, abutting the first layer, including an opencell foam material; a third layer, abutting the second layer, includinga nonwoven material; and a fourth layer, abutting the third layer, thefourth layer being an outer moisture transfer material that isencapsulated for waterproofing, wherein the combination of layers isbreathable and enables moisture vapor to be transferred through theapparel from the first layer through the fourth layer so as to keep theindividuals dry, wherein at least one of the first through fourth layershas reversible enhanced thermal properties.
 2. The moisture transferapparel according to claim 1, wherein at least two of the first, second,third and fourth layers are attached to each other by lamination.
 3. Themoisture transfer apparel according to claim 1, wherein at least two ofthe first, second, third and fourth layers are attached to each other bymechanical bonding.
 4. The moisture transfer apparel according to claim1, wherein the fourth layer is laminated to the nonwoven of the thirdlayer.
 5. The moisture transfer apparel according to claim 1, whereinthe second layer and third layer are formed as an elastomeric compositehaving the nonwoven material combined with the open cell foam materialin a single process.
 6. The moisture transfer apparel according to claim1, wherein the second layer has reversible enhanced thermal properties.7. The moisture transfer apparel according to claim 1, wherein the outermoisture transfer material is selected from a group consisting of cottonand a cotton blend.
 8. The moisture transfer apparel according to claim1, wherein the outer moisture transfer material comprises syntheticfibers.
 9. The moisture transfer apparel according to claim 1, furthercomprising a membrane, abutting the foam material, for providing eitherwarmth or cooling.
 10. The moisture transfer apparel according to claim1, wherein a membrane is applied to the second layer so that it hasreversible thermal enhanced properties.
 11. A moisture transfer apparelaccording to claim 1, wherein the second layer includes a breathablemembrane.
 12. A moisture transfer apparel according to claim 1, whereinthe third layer includes a breathable membrane.
 13. A moisture transferapparel according to claim 1, wherein the second layer includes athermal insulating material.
 14. A moisture transfer apparel accordingto claim 1, wherein the third layer includes a thermal insulatingmaterial.
 15. A moisture transfer apparel to be worn by individualsengaged in activities that generate moisture comprising, on at least aportion of the apparel, a combination of layers comprising: a firstlayer, closest to the individual, the first layer being an innermoisture transfer material; a second layer, abutting the first layer,including an open cell foam material; a third layer, abutting the secondlayer, including a nonwoven material; and a fourth layer, abutting thethird layer, the fourth layer being an outer moisture transfer materialthat is selected from fabrics that are structurally knitted or woven torepel water, wherein the combination of layers is breathable and enablesmoisture vapor to be transferred through the apparel from the firstlayer through the fourth layer so as to keep the individuals dry,wherein at least one of the first through fourth layers has reversibleenhanced thermal properties.
 16. The moisture transfer apparel accordingto claim 15, wherein the second layer has reversible enhanced thermalproperties.
 17. The moisture transfer apparel according to claim 15,further comprising a membrane, abutting the foam material, for providingeither warmth or cooling.
 18. The moisture transfer apparel according toclaim 15, wherein a membrane is applied to the second layer so that ithas reversible thermal enhanced properties.
 19. A moisture transferapparel to be worn by individuals engaged in activities that generatemoisture comprising, on at least a portion of the apparel, a combinationof layers comprising; a first layer, closest to the individual, thefirst layer being an inner moisture transfer material; a second layer,abutting the first layer, including an open cell foam material; a thirdlayer, abutting the second layer, including a nonwoven material; and afourth layer, abutting the third layer, the fourth layer being an outermoisture transfer material that is encapsulated for waterproofing,wherein the combination of layers is breathable and enables moisturevapor to be transferred through the apparel from the first layer throughthe fourth layer so as to keep the individuals dry, wherein the secondlayer is treated with microencapsulation technology which can adjust totemperature changes.
 20. A moisture transfer apparel to be worn byindividuals engaged in activities that generate moisture comprising, onat least a portion of the apparel, a combination of layers comprising: afirst layer, closest to the individual, the first layer being an innermoisture transfer material; a second layer, abutting the first layer,including an open cell foam material; a third layer, abutting the secondlayer, including a nonwoven material; and a fourth layer, abutting thethird layer, the fourth layer being an outer moisture transfer materialthat is selected from fabrics that are structurally knitted or woven torepel water, wherein the combination of layers is breathable and enablesmoisture vapor to be transferred through the apparel from the firstlayer through the fourth layer so as to keep the individuals dry,wherein the second layer is treated with microencapsulation technologywhich can adjust to temperature changes.